Cutting tool

ABSTRACT

A cutting tool includes a tool body having a first end engageable with a workpiece and a second end engageable with a spindle of a power tool. A blade extends outwardly from the first end of the tool body and including a cutting edge, the cutting edge being engageable with a workpiece to cut the workpiece. A bit, including a drive shaft and a cutting end extends along an axis of the tool body. The drive shaft extends axially outwardly beyond the first end of the tool body and terminates at the cutting end. The cutting end has a maximum cross-sectional width greater than a maximum cross-sectional width of the drive shaft, and an axial distance from the first end of the tool body to the cutting end is greater than a maximum cutting depth of the cutting tool.

RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 12/641,595, filed Dec. 18, 2009, now U.S. Pat. No. 8,123,443,which is a continuation of U.S. patent application Ser. No. 11/716,081,filed Mar. 9, 2007, now U.S. Pat. No. 7,637,703, which claims priorityto U.S. Provisional Patent Application Ser. No. 60/781,099, filed Mar.10, 2006, the entire contents of which are hereby incorporated byreference.

FIELD OF THE INVENTION

The present invention relates to cutting tools and, more particularly,to a rotary cutting tool for a power tool.

SUMMARY

In some embodiments, the invention provides a cutting tool for cutting aworkpiece. The cutting tool can include a tool body having a first endand a second end and defining an axis extending through the first endand the second end, a rim extending circumferentially around the firstend of the tool body, a first pair of openings extending axially throughthe body and opening through the rim, a second pair of openingsextending axially through the tool body and opening through the rim, anda first blade supported on the rim adjacent to one of the first pair ofopenings, and a second blade supported on the rim adjacent to another ofthe first pair of openings. In some embodiments, the second pair ofopenings provides access to plugs cut from the workpiece and supportedin the tool body. In some such embodiments, the one of the first pair ofopenings and the other of the first pair of openings are spacedcircumferentially around the rim by about 180 degrees.

The present invention also provides a cutting tool including a tool bodyhaving a first end and a second end and defining an axis extendingthrough the first end and the second end, a rim extendingcircumferentially around the first end of the tool body, and a bladeremovably supported on the rim. In some embodiments, one of the bladeand the tool body defines a recess and an other of the blade and thetool body includes an outwardly extending projection engageable in therecess to secure the blade to the tool body. In some such embodiments,the projection is wedge-shaped.

The present invention further provides a cutting tool including a toolbody having a first end engageable with a workpiece and a second endengageable with a spindle of a power tool. The tool body includes first,second, and third gullets that open through the first end of the toolbody and are spaced asymmetrically around a circumference of the firstend. The cutting tool also includes a blade extending outwardly from thefirst end of the tool body adjacent to the first gullet.

The present invention also provides a cutting tool including a tool bodyhaving a first end engageable with a workpiece and a second endengageable with a spindle of a power tool. The cutting tool alsoincludes a first blade extending outwardly from the first end of thetool body and including a cutting edge having a first width. The cuttingtool further includes a second blade extending outwardly from the firstend of the tool body and having a cutting edge with a second width. Thefirst width is greater than the second width.

The present invention further provides a cutting tool including a toolbody having a first end, a second end, and an axis extendingtherebetween. The second end is engageable with a spindle of a powertool. The cutting tool also includes a blade extending outwardly fromthe first end of the tool body and having a cutting edge. The cuttingedge is engageable with a workpiece to cut the workpiece. The cuttingtool also includes a spade bit including a cutting edge and a driveshaft. The drive shaft extends outwardly from the tool body beyond thefirst end of the tool body. The cutting edge has a width greater than awidth of the drive shaft.

The present invention also provides a cutting tool including a tool bodyhaving a first end engageable with a workpiece and a second endengageable with a spindle of a power tool. The tool body defines an axisextending between the first end and the second end. The cutting toolalso includes a blade extending outwardly from the first end of the toolbody and having a cutting edge sloping toward the second end of the toolbody from a radially inner tip toward a radially outer tip.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of a cutting tool according to someembodiments of the present invention and a plug cut from a workpiece bythe cutting tool.

FIG. 2 is another front perspective view the cutting tool shown in FIG.1 with the plug supported in the cutting tool.

FIG. 3 is a side view of a portion of the cutting tool shown in FIG. 1.

FIG. 4 is an enlarged side view of a portion of the cutting tool shownin FIG. 1.

FIG. 5 is an enlarged side view of a portion of the cutting tool shownin FIG. 1.

FIG. 6 is a perspective view of a cutting tool according to an alternateembodiment of the present invention.

FIG. 7 is a front view of the cutting tool shown in FIG. 6.

FIG. 8 is a side view of the cutting tool shown in FIG. 6.

FIG. 9 is perspective view of a portion of the cutting tool shown inFIG. 6.

FIG. 10 is a perspective view of the cutting tool shown in FIG. 6.

FIG. 11 is a perspective view of a cutting tool according to anotheralternate embodiment of the present invention.

FIG. 12 is another perspective view of the cutting tool shown in FIG.11.

FIG. 13 is a perspective view of a cutting tool according to anotheralternate embodiment of the present invention.

FIG. 14 is another perspective view of the cutting tool shown in FIG.13.

FIG. 15 is an enlarged perspective view of a portion of the cutting toolshown in FIG. 13 supporting a blade.

FIG. 16 is an enlarged perspective view of a portion of the cutting toolshown in FIG. 13 with the blade removed.

FIG. 17 is an enlarged front view of a portion of the cutting tool shownin FIG. 13 with the blade removed.

FIG. 18 is an enlarged view of the blade shown in FIG. 13.

FIG. 19 is a side view of a spade bit.

FIG. 20 is a side view of a twist bit.

FIG. 21 is a side view of a circular saw blade.

FIG. 22 is an enlarged view of a portion of the circular saw blade shownin FIG. 21.

FIG. 23 is a perspective view of a cutting tool according to anotheralternate embodiment of the present invention.

FIG. 24A is an enlarged view of a blade of the cutting tool shown inFIG. 23.

FIG. 24B is an enlarged view of another blade of the cutting tool shownin FIG. 23.

FIG. 24C is an enlarged view of another blade of the cutting tool shownin FIG. 23.

FIG. 25A is a cross-sectional view of a workpiece cut using the bladeshown in FIG. 24A.

FIG. 25B is a cross-sectional view of a workpiece cut using the bladeshown in FIG. 24B.

FIG. 25C is a cross-sectional view of a workpiece cut using the bladeshown in FIG. 24C.

FIG. 25D is a cross-sectional view of a workpiece cut using all of theblades shown in FIGS. 24A-24C.

FIG. 26 is a perspective view of a cutting tool according to anotheralternate embodiment of the present invention.

FIG. 27 is a side view of the cutting tool shown in FIG. 26.

FIG. 28A is an enlarged view of a blade of the cutting tool shown inFIG. 26.

FIG. 28B is an enlarged view of another blade of the cutting tool shownin FIG. 26.

FIG. 29A is a cross-sectional view of a workpiece cut using the bladeshown in FIG. 28A.

FIG. 29B is a cross-sectional view of a workpiece cut using the bladeshown in FIG. 28B.

FIG. 29C is a cross-sectional view of a workpiece cut using both of theblades shown in FIGS. 28A and 28B.

FIG. 30A is a perspective view of a cutting tool according to anotheralternate embodiment of the present invention.

FIG. 30B is a top view of the cutting tool shown in FIG. 30A.

FIG. 31 is an enlarged perspective view of a portion of the cutting toolshown in FIG. 30A.

FIG. 32A is an enlarged view of a blade of the cutting tool shown inFIG. 30A.

FIG. 32B is an enlarged view of another blade of the cutting tool shownin FIG. 30A.

FIG. 33A is a top perspective view of a cutting tool according toanother alternate embodiment of the present invention.

FIG. 33B is a bottom perspective view of the cutting tool shown in FIG.33A.

FIG. 33C is a side view of the cutting tool shown in FIG. 33A.

FIG. 33D is another side view of the cutting tool shown in FIG. 33A.

FIG. 34A is an exploded top perspective view of the cutting tool shownin FIG. 33A.

FIG. 34B is an exploded bottom perspective view of the cutting toolshown in FIG. 33A.

FIG. 34C is an exploded side view of the cutting tool shown in FIG. 33A.

FIG. 34D is another exploded side view of the cutting tool shown in FIG.33A.

FIG. 35A is a top perspective view of a cutting tool according to analternate embodiment of the present invention.

FIG. 35B is a bottom perspective view of the cutting tool shown in FIG.35A.

FIG. 35C is a side view of the cutting tool shown in FIG. 35A.

FIG. 35D is another side view of the cutting tool shown in FIG. 35A.

FIG. 36 is a side view of a power tool for use with a cutting tool.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” and “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items.

Unless specified or limited otherwise, the terms “mounted,” “connected,”“supported,” and “coupled” and variations thereof are used broadly andencompass both direct and indirect mountings, connections, supports, andcouplings. Further, “connected” and “coupled” are not restricted tophysical or mechanical connections or couplings.

In addition, it is to be understood that phraseology and terminologyused herein with reference to device or element orientation (such as,for example, terms like “front,” “rear,” “top,” “bottom,” “lower”, “up,”“down,” etc.) are only used to simplify description of the presentinvention, and do not alone indicate or imply that the device or elementreferred to must have a particular orientation. The elements of thepresent invention can be installed and operated in any orientationdesired. In addition, terms such as “first”, “second,” and “third” areused herein for purposes of description and are not intended to indicateor imply relative importance or significance.

FIGS. 1-5 illustrate a cutting tool 10, such as, for example, ahole-saw, for operation with a power tool (e.g., a drill, adriver-drill, a screwdriver, and the like). In one embodiment, the powertool may be similar to, for example, the power tool 100 illustrated inFIG. 36. In some embodiments, the cutting tool 10 is operable to cutholes in a workpiece and/or to remove plugs 11 from the workpiece.

As shown in FIGS. 1-5, the cutting tool 10 includes a generallycylindrically-shaped body 12 having a first or workpiece-engaging end 14and a second or rearward end 16. The first end includes a rim 18defining an opening 20 and the second end 16 includes a base 21.

A connecting structure 22 is supported on the second end 16 of the body12 and includes an elongated rearwardly-extending drive shaft 24configured to be received in a chuck or spindle of a power tool. Forexample, the connecting structure 22 may be received by a spindle 102 ofthe power tool 100 illustrated in FIG. 36. In some embodiments, such asthe illustrated embodiment of FIGS. 1-5, fasteners can be used to securethe connecting structure 22 to the body 12 of the cutting tool 10. Inother embodiments, the body 12 and the connecting structure 22 can beintegrally formed.

In the illustrated embodiment of FIGS. 1-5, the drive shaft 24 has asubstantially hexagonal cross-sectional shape and includes six flatsides 26. In other embodiments, the drive shaft 24 can have othercross-sectional shapes, such as, for example, round, triangular,rectangular, trapezoidal, or any other polygonal shape, oval, irregular,and the like and can include one or more flat sides 26.

In the illustrated embodiment of FIGS. 1-5, the connecting structure 22also includes a groove 28 extending circumferentially around a rearwardend of the drive shaft 24 for engagement with locking elements in achuck or spindle of a power tool. In other embodiments, the connectingstructure 22 can include other recesses and protrusions and combinationsof recesses and protrusions for engagement with locking elements inchucks of power tools for securing the cutting tool 10 to the powertool.

In some embodiments, such as the illustrated embodiment of FIGS. 1-5, abit 30 extends forwardly from the first end 14 of the body 12 andoutwardly from the body 12 beyond the rim 18. In the illustratedembodiment of FIGS. 1-5, the bit 30 is configured as a twist drill bitand is generally aligned with the drive shaft 24 along a longitudinalaxis 32. In other embodiments, the bit 30 and the drive shaft 24 canhave other relative orientations and can other configurations, such as,for example, a spade bit configuration, ship auger bit configuration,etc.

As shown in FIGS. 1-5, openings or gullets 36 can be spacedcircumferentially around the body 12 and can extend axially through thebody 12 from the rim 18 toward the base 21. In the illustratedembodiment of FIGS. 1-5, the body 12 includes four gullets 36 with afirst gullet 36A being spaced a distance A from a second, adjacentgullet 36B, the second gullet 36B being spaced a second distance B froma third gullet 36C, the third gullet 36C being spaced the first distanceA from a forth gullet 36D, and the fourth gullet 36D being spaced thesecond distance B from the first gullet 36A. In the illustratedembodiment of FIGS. 1-5, the first distance A is substantially greaterthan the second distance B. In other embodiments, the body 12 caninclude five or more gullets 36 spaced at regular or irregular intervalsaround the circumference of the body 12.

As shown in FIGS. 1-5, each of the gullets 36A-36D includes an openfirst end 38 opening through the rim 18 and a closed second end 40. Inthe illustrated embodiment of FIGS. 1-5, the second ends 40 of thegullets 36A-36D are generally arcuately shaped and are positionedadjacent to the base 21 of the body 12. In other embodiments, the secondends 40 can have any other shape desired, such as, for example, flat,sloped, angled, pointed, irregular, and the like and can be positionedat any point between the first and second ends 14, 16 of the body 12.

In the illustrated embodiment of FIGS. 1-5, cutting blades 44 aresupported on the first end 14 of the body 12 adjacent to the second andforth gullets 36B, 36D. In embodiments such as the illustratedembodiment in which the cutting tool 10 is rotated about the axis 32 ina counterclockwise direction, the cutting blades 44 are located adjacentto trailing edges 46 of the second and fourth gullets 36B, 36D. In otherembodiments, the cutting tool 10 can include one, three, four, or morecutting blades 44 positioned circumferentially around the rim 18 atregular or irregular intervals. In these other embodiments, the cuttingblades 44 can be positioned adjacent to leading edges 48 of the gullets36, the trailing edges 46 of the gullets 36, or at any other positionaround the circumference of the rim 18.

In some embodiments, blades 44 are not positioned adjacent to one ormore of the gullets 36. For example, in the illustrated embodiment ofFIGS. 1-5, the trailing and leading edges 46, 48 of the first and thirdgullets 36A, 36C are relatively smooth and do not include blades 44. Inthese embodiments, an operator can insert his fingers through the firstand third gullets 36A, 36C and into the body 12 to remove chips or plugs11 without contacting the blades 44. More particularly, as shown inFIGS. 1-2, in some embodiments, the cutting tool 10 can be used toremove a plug 11 from a workpiece. In these embodiments, after thecutting operation is complete, an operator can grasp the plug 11 throughthe second and fourth gullets 36B, 36D and remove the plug 11 from thebody 12 before resuming operation of the cutting tool 10.

During operation, an operator secures the connecting structure 22 of thecutting tool 10 to a power tool and positions the cutting tool 10 abovea workpiece. The operator then centers the bit 30 above the intendedcutting location and activates the power tool to rotate the cutting tool10 about the axis 32 of the drive shaft 24. As the cutting tool 10rotates, the bit 30 drills a locating hole in the workpiece and orientsthe body 12 of the cutting tool 10 in a desired position above theworkpiece.

Continued forward movement of the cutting tool 10 moves the blades 44into engagement with the workpiece. As the blades 44 rotate, the blades44 cut a circular path in the workpiece. Chips and sawdust formed duringthe cutting are directed radially outwardly through the gullets 36.After a hole is cut in the workpiece, the operator can remove the plugand/or chips from the body 12 of the cutting tool 10 as described above.

FIGS. 6-10 illustrate an alternate embodiment of a cutting tool 210according to the present invention. The cutting tool 210 shown in FIGS.6-10 is similar in many ways to the illustrated embodiments of FIGS. 1-5described above. Accordingly, with the exception of mutuallyinconsistent features and elements between the embodiment of FIGS. 6-10and the embodiments of FIGS. 1-5, reference is hereby made to thedescription above accompanying the embodiments of FIGS. 1-5 for a morecomplete description of the features and elements (and the alternativesto the features and elements) of the embodiment of FIGS. 6-10. Featuresand elements in the embodiment of FIGS. 6-10 corresponding to featuresand elements in the embodiments of FIGS. 1-5 are numbered in the 200series.

In the illustrated embodiment of FIGS. 6-10, the cutting tool 210includes four openings or gullets 236 spaced circumferentially aroundthe body 212. The gullets 236 extend axially through the body 212 fromthe rim 218 toward the base 221 and are oriented at a non-perpendicularangle α with respect to the base 221 of the cutting tool 210. Morespecifically, the leading edges 248 of the gullets 236 are oriented atan angle α of between about 30 degrees and about 60 degrees with respectto the base 221 of the cutting tool 210. For example, in someembodiments, the gullets 236 are oriented at a non-perpendicular angle αwith respect to the axis 232 extending perpendicularly from the base212.

In some embodiments, such as the illustrated embodiment of FIGS. 6-10,cutting blades 244 are supported on the first end 214 of the body 212adjacent to each of the first, second, third, and fourth gullets 236A,236B, 236C, 236D. In other embodiments, the cutting tool 210 can includeone, two, three, five, or more cutting blades 244 positioned adjacent tothe leading or trailing edges 248, 246 of the gullets 236 or at anyother location around the circumference of the rim 218.

During operation, chips cut from the workpiece are directed radiallyoutwardly through the gullets 236. In some embodiments, such as theillustrated embodiment of FIGS. 6-10 in which the gullets 236 areoriented at a non-perpendicular angle α with respect to the base 221 ofthe body 212, chips cut from the workpiece travel circumferentiallytoward a downstream gullet 236 before being directed radially outwardlythrough the gullet 236 and out of the body 212.

FIGS. 11 and 12 illustrate an alternate embodiment of a cutting tool 310according to the present invention. The cutting tool 310 shown in FIGS.11 and 12 is similar in many ways to the illustrated embodiments ofFIGS. 1-10 described above. Accordingly, with the exception of mutuallyinconsistent features and elements between the embodiment of FIGS. 11and 12 and the embodiments of FIGS. 1-10, reference is hereby made tothe description above accompanying the embodiments of FIGS. 1-10 for amore complete description of the features and elements (and thealternatives to the features and elements) of the embodiment of FIGS. 11and 12. Features and elements in the embodiment of FIGS. 11 and 12corresponding to features and elements in the embodiments of FIGS. 1-10are numbered in the 300 series.

As shown in FIGS. 11 and 12, the cutting tool 310 can include first,second, third and fourth gullets 336A, 336B, 336C, 336D spacedcircumferentially around the rim 318 and extending through the body 312.In the illustrated embodiment of FIGS. 11 and 12, the first and thirdgullets 336A, 336C are spaced apart by about 180 degrees and areoriented at a non-perpendicular angle of between about 30 degrees andabout 60 degrees with respect to the base 321 of the body 312. Thesecond and fourth gullets 336B, 336D are spaced apart by about 180degrees and are oriented at a perpendicular angle with the respect tothe base 321 of the body 312.

In some embodiments, such as the illustrate embodiment of FIGS. 11 and12 the first gullet 336A is spaced a distance A from the second gullet336B, the second gullet 336B is spaced a second distance B from thethird gullet 336C, the third gullet 336C is spaced the first distance Afrom the forth gullet 336D, and the fourth gullet 336D is spaced thesecond distance B from the first gullet 36A. In the illustratedembodiment of FIGS. 11 and 12, the second distance B is substantiallygreater than the first distance A. In other embodiments, the body 12 caninclude five or more gullets 336 spaced at regular or irregularintervals around the circumference of the body 312.

In the illustrated embodiment of FIGS. 11 and 12, cutting blades 344 aresupported on the first end 314 of the body 312 adjacent to the first andthird gullets 336A, 336C. In embodiments such as the illustratedembodiment in which the cutting tool 310 is rotated in acounterclockwise direction, the cutting blades 344 are located adjacentto trailing edges 346 of the first and third gullets 336A, 336C. Inother embodiments, the cutting tool 10 can include one, three, four, ormore cutting blades 344 positioned circumferentially around the rim 318at regular or irregular intervals. In these other embodiments, thecutting blades 344 can be positioned adjacent to leading edges 348 ofthe gullets 336, the trailing edges 346 of the gullets 336, or at anyother position around the circumference of the rim 318.

As shown in FIGS. 11 and 12, the body 312 of the cutting tool 310 canalso include openings 360 positioned between the gullets 336. Theopenings 360 extend radially through the body 312 and communicatebetween the interior and the exterior of the body 312 and facilitate theremoval of plugs and chips from the body 312.

FIGS. 13-18 illustrate an alternate embodiment of a cutting tool 410according to the present invention. The cutting tool 410 shown in FIGS.13-18 is similar in many ways to the illustrated embodiments of FIGS.1-12 described above. Accordingly, with the exception of mutuallyinconsistent features and elements between the embodiment of FIGS. 13-18and the embodiments of FIGS. 1-12, reference is hereby made to thedescription above accompanying the embodiments of FIGS. 1-12 for a morecomplete description of the features and elements (and the alternativesto the features and elements) of the embodiment of FIGS. 13-18. Featuresand elements in the embodiment of FIGS. 13-18 corresponding to featuresand elements in the embodiments of FIGS. 1-12 are numbered in the 400series.

As shown in FIGS. 13-18, the cutting tool 410 can include a tool holder462 supported on the first end 414 of the body 412 adjacent to a gullet436 for supporting a removable cutting blade 444. In the illustratedembodiment of FIGS. 13-18, the tool holder 462 includes opposed firstand second fingers 464, 466 and an opening 468 defined between the firstand second fingers 464, 466. Tracks 470 extend along the interior sidesof the first and second fingers 464, 466. As shown in FIGS. 16 and 17,the tracks 470 can have a substantially V-shaped cross-sectional shapeand can slope inwardly from a first end 472 toward a second end 474. Inother embodiments, one or both of the tracks 470 can have any othercross-sectional shape desired, such as, for example, square, triangular,rectangular, trapezoidal, or any other polygonal shape, arcuate,irregular, and the like.

In some embodiments, such as the illustrated embodiment of FIGS. 13-18,the blade 444 can include a blade body 478 having a cutting edge 480 andtracks 482 extending along the exterior edges of the blade body 478 forengagement with the tool holder 462 of the cutting tool 410. In theillustrated embodiment of FIGS. 13-18, the tracks 482 of the blade 444have a substantially V-shaped cross-sectional shape and slope inwardlyfrom a first end 484 toward a second end 486 for locking engagement withcorrespondingly shaped tracks 470 on the tool holder 462 to secure theblade 444 to the tool body 412. In other embodiments, one or both of thetracks 482 can have any other cross-sectional shape desired, such as,for example, square, triangular, rectangular, trapezoidal, or any otherpolygonal shape, arcuate, irregular, and the like. In still otherembodiments, one or both of the blade 444 and the tool holder 462 caninclude a magnet and/or can be magnetized to secure the blade 444 to thetool holder 462.

In embodiments such as the illustrated embodiment of FIGS. 13-18 havinga removable blade 444, an operator can remove damaged or worn blades 444and replace the damaged or worn blades 444 to maintain a relativelysharp cutting edge 480.

In some embodiments, a removable blade may be configured to fit on othertypes of cutting tools. For example, as shown in FIG. 19, a removableblade 502 may be positioned on a cutting edge 504 of a flat boring bitor a spade bit 500. Alternatively, as shown FIG. 20, a removable blade512 may be positioned on a tip 514 of a twist bit 510. Alternatively, asshown in FIGS. 21 and 22, a removable blade 522 may be positioned on atleast some cutting blades 524 of a circular saw blade 520. Similar tothe removable blade 444 illustrated in FIGS. 13-18, if any of theremovable blades 502, 512, 522 become damaged or worn, an operator maysimply remove the damaged or worn blades 502, 512, 522 and replace thedamaged or worn blades 502, 512, 522 with new blades.

FIGS. 23-24C illustrates an alternate embodiment of a cutting tool 610according to the present invention. The cutting tool 610 shown in FIGS.23-24C is similar in many ways to the illustrated embodiments of FIGS.1-18 described above. Accordingly, with the exception of mutuallyinconsistent features and elements between the embodiment of FIGS.23-24C and the embodiments of FIGS. 1-18, reference is hereby made tothe description above accompanying the embodiments of FIGS. 1-18 for amore complete description of the features and elements (and thealternatives to the features and elements) of the embodiment of FIGS.23-24C. Features and elements of FIGS. 23-24C corresponding to featuresand elements in the embodiments of FIGS. 1-18 are numbered in the 600series.

In the illustrated embodiment of FIGS. 23-24C, the cutting tool 610includes a first gullet 636A, a second gullet 636B, and a third gullet636C spaced circumferentially around the body 612. As shown in FIG. 23,each gullet 636A, 636B, 636C can be spaced regularly (e.g.,approximately 120 degrees apart) around the circumference of the body612 from the other gullets 636A, 636B, 636C and can be oriented at aperpendicular angle with respect to the base 621 of the cutting tool610. In other embodiments, the gullets 636A, 636B, 636C can be spacedirregularly and/or can be oriented at a non-perpendicular angle withrespect to the base 621 of the cutting tool 610.

In some embodiments, such as the embodiment of FIGS. 23-24C, cuttingblades 644 are supported on the first end 614 of the body 612 adjacentto each of the first, second, and third gullets 636A, 636B, 636C.Referring to FIGS. 24A-24C, each cutting blade 644 includes an outer tip688 positioned radially outwardly from the rim 618, an inner tip 690positioned radially inwardly from the rim 618, and a cutting edge 692extending between the outer tip 688 and the inner tip 690. In theillustrated embodiment, the cutting edges 692 are generally flat. Inother embodiments, the cutting edges 692 may be concave, convex, jagged,irregular, or the like.

As shown in FIG. 23A, the outer tip 688A of the first cutting blade 644Ais relatively higher (i.e., further from the base 621) than the innertip 690A such that the first cutting blade 644A is beveled inwardly. Inother words, the cutting edge 692A slopes towards the base 621 from theouter tip 688A to the inner tip 690A. In the embodiment illustrated inFIG. 22, the cutting edge 692A of the first cutting blade 644A is slopedsuch that the inner tip 690A is higher than the rim 618 of the cuttingtool 610. In other embodiments, the cutting edge 692A may be sloped alesser or greater amount such that the inner tip 690A is even higherthan, substantially equal to, or below the rim 618.

As shown in FIG. 23B, the outer tip 688B of the second cutting blade644B is at substantially the same height as the inner tip 690B such thatthe cutting edge 692B of the second cutting blade 644B is substantiallyparallel to the base 621. In the embodiment illustrated in FIG. 22, thesecond cutting blade 644B is configured such that the cutting edge 692Bof the second cutting blade 644B is at a height (i.e., distance from thebase 621) between the outer tip 688A and the inner tip 690A of the firstcutting blade 644A. In other embodiments, the cutting edge 692B of thesecond cutting blade 644B may be positioned at a height substantiallyequal to the height of the outer tip 688A or the inner tip 690A of thefirst cutting blade 644A, or at a height substantially below the heightof the inner tip 690A.

As shown in FIG. 23C, the outer tip 688C of the third cutting blade 644Cis relatively lower (i.e., closer to the base 621) than the inner tip690C such that the second cutting blade 644C is beveled outwardly. Inother words, the cutting edge 692C slopes towards the base 621 from theinner tip 690C to the outer tip 688C. In the embodiment illustrated inFIG. 22, the cutting edge 629C of the third cutting blade 644C is slopedsuch that the outer tip 688C is higher than the rim 618 of the cuttingtool 610. In other embodiments, the cutting edge 692C may be sloped alesser or greater amount such that the outer tip 688C is even higherthan, substantially equal to, or below the rim 618. Furthermore, asshown in FIG. 22, the outer tip 688C of the third cutting blade 644C canbe at substantially the same height as the inner tip 690A of the firstcutting blade 644A, and the inner tip 690C of the third cutting blade644C can be at substantially the same height as the outer tip 688A ofthe first cutting blade 644A. In other embodiments, some or all of theinner and outer tips 688, 690 of the first, second, and third cuttingblades 644 can be at substantially similar or different heights.

FIGS. 25A-25D illustrate a portion of a workpiece 104 cut using thecutting tool 610 shown in FIGS. 22-23C. For example, FIG. 25Aillustrates a cross-section of the workpiece 104 having a cut-outportion 106A that can result from using the first cutting blade 644A,FIG. 25B illustrates a cross-section of the workpiece 104 having acut-out portion 106B that can result from using the second cutting blade644B, and FIG. 25C illustrates a cross-section of the workpiece 610having a cut-out portion 106C that can result from using the thirdcutting blade 644C. A resultant cut-out portion 106D of the workpiece104 using all three cutting blades 644A, 644B, 644C, such as, forexample, by using the cutting tool 610 illustrated in FIG. 22, is shownin FIG. 25D.

FIGS. 26-28B illustrate an alternate embodiment of a cutting tool 710according to the present invention. The cutting tool 710 shown in FIGS.26-28B is similar in many ways to the illustrated embodiments of FIGS.1-18 and 23-24C described above. Accordingly, with exception of mutuallyinconsistent features and elements between the embodiment of FIGS.26-28B and the embodiments of FIGS. 1-18 and 23-24C, reference is herebymade to the description above accompanying the embodiments of FIGS. 1-18and 23-24C for a more complete description of the features and elements(and the alternatives to the features and elements) of the embodiment ofFIGS. 26-28B. Features and elements of FIGS. 26-28B corresponding tofeatures and elements in the embodiments of FIGS. 1-18 and 23-24C arenumbered in the 700 series.

In the illustrated embodiment of FIGS. 26-28B, the cutting tool 710includes a spade bit 730, a first gullet 736A, a second gullet 736B, athird gullet 736C, and a fourth gullet 736D. The spade bit 730 includesa cutting edge 794, a spade body 795, and a drive shaft 796. The spadebody 795 and the drive shaft 796 may be, for example, cylindrical,rectangular, octagonal, hexagonal, square, oblong, or any combinationthereof. In the embodiment illustrated, the cutting edge 794 has a widththat is substantially greater than a width of the drive shaft 796. Thespade body 795 serves as a transition between the cutting edge 794 andthe drive shaft 796 and, as such, includes a first portion 797 having awidth substantially equal to the width of the cutting edge 794 and asecond portion 798 having a width substantially equal to the width ofthe drive shaft 796.

In some embodiments, such as the embodiment illustrated in FIGS. 26 and27, the drive shaft 796 extends beyond the rim 718 of the cutting tool710 such that both portions 797, 798 of the spade body 795 arepositioned above the rim 718. In such an embodiment, an operator maycompletely remove a plug from the body 712 of the cutting tool 710 priorto the plug contacting the cutting edge 794 and first portion 797 of thespade bit 730. The operator may then agitate or wiggle the plug afterthe plug has cleared the body 712 to release the plug from the firstportion 797 and the cutting edge 794 of the spade bit 730. In otherembodiments, only a portion of the plug may clear the body 712 of thecutting tool 710 prior to the plug contacting the first portion 797and/or the cutting edge 794 of the spade bit 730.

In the illustrated embodiment of FIGS. 26-28B, cutting blades 744 aresupported on the first end 714 of the body 712 adjacent to each of thefirst and third gullets 736A, 736C. As shown in FIG. 28A, the outer tip788A of the first cutting blade 744A is relatively higher than the innertip 790A such that the first cutting blade 744A is beveled inwardly,similar to the first cutting blade 644A illustrated in FIG. 23A. Asshown in FIG. 28B, the outer tip 788B of the second cutting blade 744Bis relatively lower than the inner tip 790B such that the second cuttingblade 744B is beveled outwardly, similar to the third cutting blade 644Cillustrated in FIG. 23C.

FIGS. 29A-29B illustrate a portion of a workpiece 108 cut using thecutting tool 710 shown in FIGS. 26-28B. For example, FIG. 29Aillustrates a cross-section of the workpiece 108 having a cut-outportion 110A that can result from using the first cutting blade 744A,and FIG. 29B illustrates a cross-section of the workpiece 108 having acut-out portion 110B that can result from using the second cutting blade744B. A resultant cut-out area 110C of the workpiece 108 using bothcutting blades 744A, 744B, such as, for example by using the cuttingtool 710 illustrated in FIGS. 26 and 27, is shown in FIG. 29C.

FIGS. 30A-32B illustrate an alternate embodiment of a cutting tool 810according to the present invention. The cutting tool 810 as shown inFIGS. 30A-32B is similar in many ways to the illustrated embodiments ofFIGS. 1-18, 23-24C, and 26-28B described above. Accordingly, withexception of mutually inconsistent features and elements between theembodiment of FIGS. 30A-32B and the embodiments of FIGS. 1-18, 23-24C,and 26-28B, reference is hereby made to the description aboveaccompanying the embodiments of FIGS. 1-18, 23-24C, and 26-28B for amore complete description of the features and elements (and thealternatives to the features and elements) of the embodiment of FIGS.30A-32B. Features and elements in the embodiment of FIGS. 30A-32Bcorresponding to features and elements in the embodiments of FIGS. 1-18,23-24C, and 26-28B are numbered in the 800 series.

In the illustrated embodiment of FIGS. 30A-32B, the cutting tool 810includes a first gullet 836A and a second gullet 836B. Cutting blades844 are supported on the first end 814 of the body 812 adjacent to eachof the first and second gullets 836A, 836B. In some embodiments, thecutting blades 844 may include cutting edges 892 having inward bevels oroutward bevels, or cutting edges 892 that are substantially parallel tothe base 821 of the cutting tool 810.

As shown in FIG. 32A, the cutting edge 892A of the first cutting blade844A has a width X. In some embodiments, such as the embodimentillustrated in FIG. 32B, the second cutting blade 844B can include ashaved inner tip 890B. As shown in FIG. 32B, due to the shaved inner tip890B, the cutting edge 892B of the second cutting blade 844B has a widthY, which is substantially less than the width X of the cutting edge 892Aof the first cutting blade 844A. The inner tip 890B of the secondcutting blade 844B is considered “shaved” because a portion 891 of theinner tip 890B is removed from the second cutting blade 844B. In someembodiments, the inner tip 890B of the second cutting blade 844B may be,for example, ground, filed, cut, machined or the like such that theinner tip 890B of the second cutting blade 844B does not extend radiallyinwardly as far as the inner tip 890A of the first cutting blade 844A.

Referring to FIGS. 30B and 31, a cutting line 899 of the first cuttingblade 844A is shown. The cutting line 899 indicates approximately wherethe inner tip 890A of the first cutting blade 844A cuts a workpiece. Inthe illustrated embodiment, the cutting line 899 is positioned radiallyinwardly from the shaved inner tip 890B of the second cutting blade844B. In other embodiments, the cutting line 899 may be a greater or alesser distance from the shaved inner tip 890B than the amountillustrated. In still other embodiments, three or more cutting blades844 supported on the first end 814 of the body 812 may define cuttinglines that each project radially inwardly by different amounts.

Since the first cutting blade 844A cuts a workpiece along the cuttingline 899, the plug created has a diameter that is less than a distance Cbetween the inner tip 890A of the first cutting blade 844A and theshaved inner tip 890B of the second cutting blade 844B. The smallerdiameter plug allows an operator to remove the plug from the cuttingtool 810 more easily than if one of the cutting blades 844 did not havea shaved inner tip.

FIGS. 33A-34D illustrate an alternate embodiment of a cutting tool 910according to the present invention. The cutting tool 910 shown in FIGS.33A-34D is similar in many ways to the illustrated embodiments of FIGS.1-18, 23-24C, 26-28B, and 30A-32B described above. Accordingly, with theexception of mutually inconsistent features and elements between theembodiment of FIGS. 33A-34D and the embodiments of FIGS. 1-18, 23-24C,26-28B, and 30A-32B, reference is hereby made to the description aboveaccompanying the embodiments of FIGS. 1-18, 23-24C, 26-28B, and 30A-32Bfor a more complete description of the features and elements (and thealternative to the features and elements) of the embodiment of FIGS.33A-34D. Features and elements in the embodiment of FIGS. 33A-34Dcorresponding to features and elements in the embodiments of FIGS. 1-18,23-24C, 26-28B, and 30A-32B are numbered in the 900 series.

In the illustrated embodiment of FIGS. 33A-34D, the cutting tool 910includes a spade bit 930, a first long gullet 936A, a second long gullet936B, a first short gullet 936C, and a second short gullet 936D. Thespade bit 930 includes a cutting edge 994, an elongated spade body 995,and a drive shaft 996. In some embodiments, such as the embodimentillustrated, the spade body 995 is generally planar and the drive shaft996 is generally cylindrical. In other embodiments, the spade body 995and/or the drive shaft 996 may take other forms such as, for example,octagonal, hexagonal, square, oblong, or the like. In the illustratedembodiment, the spade body 995 has a width that is substantially equalto a width (e.g., diameter if the drive shaft 996 is cylindrical) of thedrive shaft 996, while the cutting edge 994 has a width substantiallygreater than both the spade body 995 and the drive shaft 996.

As shown in FIGS. 33A-34D, the long gullets 936A, 936B can be spacedabout 180 degrees circumferentially around the body. The long gullets936A, 936B are termed “long” because the long gullets 936A, 936B open onthe first end 914 of the body 912 and extend to substantially the secondend 916 of the body 912. In the illustrated embodiment, cutting blades944 are supported on the first end 914 of the body 912 adjacent to eachof the first and second long gullets 936A, 936B.

The short gullets 936C, 936D can also be spaced about 180 degreescircumferentially around the body 912. In some embodiments, the longgullets 936A, 936B and the short gullets 936C, 936D may be spaced atregular or irregular intervals such that the cutting tool 910 issymmetrical or asymmetrical. The short gullets 936C, 936D are termed“short” because the short gullets 936C, 936D open on the first end 914of the body 912 and extend only a portion of the way toward the secondend 916 of the body 912. In the embodiment illustrated, the shortgullets 936C, 936D extend slightly past a lower edge of the cuttingblades 844 such that an operator can insert his fingers through thefirst and second short gullets 936C, 936D and into a top portion of thebody 912 without contacting the cutting blades 944.

FIGS. 35A-35D illustrate an alternate embodiment of a cutting tool 1010according to the present invention. The cutting tool 1010 shown in FIGS.35A-35D is similar in many ways to the illustrated embodiments of FIGS.1-18, 23-24C, 26-28B, and 30A-34D described above. Accordingly, with theexception of mutually inconsistent features and elements between theembodiment of FIGS. 35A-33D and the embodiments of FIGS. 1-18, 23-24C,26-28B, and 30A-34D, reference is hereby made to the description aboveaccompanying the embodiments of FIGS. 1-18, 23-24C, 26-28B, and 30A-34Dfor a more complete description of the features and elements (and thealternatives to the features and elements) of the embodiment of FIGS.35A-35D. Features and elements in the embodiment of FIGS. 35A-35Dcorresponding to features and elements in the embodiments of FIGS. 1-18,23-24C, 26-28B, and 30A-34D are numbered in the 1000 series.

In the illustrated embodiment of FIGS. 35A-35D, the cutting tool 1010includes a spade bit 1030, a first gullet 1036A, and a second gullet1036B. The spade bit 1030 can be substantially similar to the spade bit930 described above with reference to FIGS. 33A-34D. In addition, thespade bit 1030 can include a removable blade 1031 on the cutting edge1094 similar to the spade bit 500 and the removable blade 502 describedabove with reference to FIG. 19.

As shown in FIGS. 35A-35D, the gullets 1036A, 1036B are spacedapproximately 180 degrees apart around the circumference of the body1012. In other embodiments, the gullets 1036A, 1036B may be spaced alesser amount such as, for example, 90 degrees apart around thecircumference of the body 1012. In some embodiments, such as theillustrated embodiment of FIGS. 35A-35D, cutting blades 1044 aresupported on the first end 1014 of the body 1012 adjacent to each of thefirst and second gullets 1036A, 1036B. The cutting blades 1044 may bebeveled similar to the cutting blades 744A, 744B illustrated in FIGS.28A and 28B, or may be substantially level with respect to the base 1021of the body 1012.

The embodiments described above and illustrated in the figures arepresented by way of example only and are not intended as a limitationupon the concepts and principles of the present invention.

Various features and advantages of the invention are set forth in thefollowing claims.

What is claimed is:
 1. A cutting tool comprising: a tool body having afirst end defining a rim, a second end, and an axis extendingtherebetween, the second end being engageable with a spindle of a powertool; a gullet formed in the tool body and including an open end open atthe rim and a closed end disposed adjacent the second end of the toolbody; a first finger formed adjacent the gullet; a second finger spacedapart from the first finger, the first finger and the second fingercooperating to define a track that extends around a portion of anopening; and a blade disposed within the opening and received by thetrack, the blade including a cutting edge, wherein one of the blade andthe tool body includes a magnet to at least partially retain the bladein the opening.
 2. The cutting tool of claim 1, wherein the gullet issubstantially U-shaped and defines a longitudinal axis that issubstantially parallel to the axis.
 3. The cutting tool of claim 1,wherein the gullet is substantially U-shaped and defines a longitudinalaxis that is oblique to the axis.
 4. The cutting tool of claim 1,wherein the track has a V-shaped cross section.
 5. The cutting tool ofclaim 1, wherein the blade includes a perimeter shaped to receive theV-shaped cross section of the track.
 6. The cutting tool of claim 1,wherein the gullet is a first of a plurality of gullets and the openingis a first of a plurality of openings.
 7. A cutting tool comprising: atool body having a first end defining a rim, a second end, and an axisextending therebetween, the second end being engageable with a spindleof a power tool; a gullet formed in the tool body and including an openend open at the rim and a closed end disposed adjacent the second end ofthe tool body; an opening formed adjacent the gullet and defining atrack having a V-shaped cross section; a blade disposed within theopening and including a perimeter shaped to receive the V-shaped crosssection of the track; a bit including a drive shaft and a cutting end,the drive shaft extending axially outwardly beyond the first end of thetool body and terminating at the cutting end, the cutting end having amaximum cross-sectional width greater than a maximum cross-sectionalwidth of the drive shaft, and wherein an axial distance from the firstend of the tool body to the cutting end is greater than a maximumcutting depth of the cutting tool.
 8. The cutting tool of claim 1,wherein the cutting edge is disposed above a plane defined by the rim.9. A cutting tool comprising: a tool body having a first end defining arim, a second end, and an axis extending therebetween, the second endbeing engageable with a spindle of a power tool; a gullet formed in thetool body and including an open end open at the rim and a closed enddisposed adjacent the second end of the tool body; a first finger formedadjacent the gullet; a second finger spaced apart from the first finger,the first finger and the second finger cooperating to define a trackthat extends around a portion of an opening; and a blade disposed withinthe opening and received by the track, the blade including a cuttingedge, a bit including a drive shaft and a cutting end, the drive shaftextending axially outwardly beyond the first end of the tool body andterminating at the cutting end, the cutting end having a maximumcross-sectional width greater than a maximum cross-sectional width ofthe drive shaft, and wherein an axial distance from the first end of thetool body to the cutting end is greater than a maximum cutting depth ofthe cutting tool.
 10. A cutting tool comprising: a tool body having afirst end defining a rim, a second end, and an axis extendingtherebetween, the second end being engageable with a spindle of a powertool; a gullet formed in the tool body and including an open end open atthe rim and a closed end disposed adjacent the second end of the toolbody; an opening formed adjacent the gullet and defining a track havinga V-shaped cross section; and a blade disposed within the opening andincluding a perimeter shaped to receive the V-shaped cross section ofthe track, wherein one of the blade and the tool body includes a magnetto at least partially retain the blade in the opening.
 11. The cuttingtool of claim 9, wherein the gullet is substantially U-shaped anddefines a longitudinal axis that is substantially parallel to the axis.12. The cutting tool of claim 9, wherein the gullet is substantiallyU-shaped and defines a longitudinal axis that is oblique to the axis.13. The cutting tool of claim 9, wherein the gullet is a first of aplurality of gullets and the opening is a first of a plurality ofopenings.
 14. The cutting tool of claim 9, wherein the cutting edge isdisposed above a plane defined by the rim.